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I have a stock '98 E-350 passenger van with a 6.8L. The van is often loaded and pulling a 6000# trailer at 8000' in the Colorado mountains. This van is not used for long trips or interstate highway travel, so while good fuel economy is desirable, it is not the priority. It has a rear axle code of 34, which indicates a standard 3.73 rear end. I am going to change the gearing and would like input on what to change it to. I'm thinking 4.30, but would like to hear your opinions.
The van is used at high elevation, often loaded with 10 - 15 adults and pulling a 6000# trailer up some rather steep climbs. A 3.73 rear end ratio seems to me like a highway/fuel economy motivated gearing. We have another van with a 7.5L and 4.10 gears, and it seems to pull better despite the slightly lower HP and torque. Since we don't do much highway driving, it made sense to look at gearing the rear end with a bigger gear to accommodate the type of work it does.
I believe when ordered new, this van came with 3.73, but could be ordered with 4.10 for towing applications. So a 4.10 should be fine. But, I think that 4.10 was a "compromise" ratio that improved towing without sacrificing fuel economy too much. That's great for applications that spend a lot of time on the highway. But, since we don't need the top end much, and are not too worried about the MPG, and since the 4.10 "compromise" doesn't take into account our 8000' elevation, I started thinking that 4.30 or 4.56 might be a better choice.
From the Novak calculator, at 70 MPH, which is about as fast as this van would ever need to go, the current 3.73 gears would have the RPM at 2925 in 3rd and 2080 in OD.
Here are the RPM calculations at 70 MPH for all of the gearing ratios that I'm considering:
I don't know how or if this would affect shift points, and if that is something that I would need to factor in. But, even the 4.56 gearing would only be moving the RPM up about 500, so none of these options seem "extreme" to me.
Mark, you seem to be the resident expert here, what are your thoughts?
Thanks again Mark. I was afraid that 4.56 might be too much...as they say, too much of a good thing... But, given the application, it makes sense. It just seems like a big jump. So, once this is done, I expect that I'll have to reprogram the computer so that my speedometer is accurate. Can someone tell me how this is done?
It's easy. Change to the 4.56 and drive it. The speedo doesn't care. It reads rear wheel speed, so the gear change doesn't affect it.
2540 RPM at 70 MPH is a bit too high for me for driving across the country, but for what you use it for I think it will work great.
To get a feel for it run the van at 70 MPH with the OD off. That will give you 2900 RPM, which is 400 more than the 4.56 will do in overdrive at 70 MPH.